| 1 | 1a. Form Structural Sections using Machines | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Use one of the following types of machines: • power press • hammer machines • section bending machine • powered rolls • special purpose machines |
| 1.3 | Confirm that the equipment is set up correctly and is ready for use by carrying out all of the following checks: • the appropriate machine is selected for the operation being performed • the machine guards and safety devices are in position and function correctly • forming tools are appropriate and in a serviceable condition (secure, correct shape, free from damage) • machine settings are suitable for the material thickness and operations to be performed |
| 1.4 | Manipulate the machine controls safely and correctly in line with operational procedures |
| 1.5 | Produce formed structural sections which contain four of the following features: • right angled bends • angular bends • curved beams • circular sections • counter curved sections • twisted section • straightening |
| 1.6 | Bend and form structural components made from three of the following forms of material: • rolled steel joists (RSJ) • angle section • channel section • structural tubes/pipes • extrusions • other specific components |
| 2 | 1b. Form Structural Sections using Machines (continued) | 2.1 | Produce components to the required specification |
| 2.2 | Produce structural components which meet all of the following quality and accuracy standards: • bend position and dimensional accuracy is within the specification tolerances • the form or sharpness of the bend conforms to best practice and/or specification without deformation or cracking • the bend conforms to the required shape/geometry (to the template profile) |
| 2.3 | Carry out quality sampling checks at suitable intervals |
| 2.4 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 2.5 | Shut down the equipment to a safe condition on conclusion of the machining activities |
| 3 | 2a. Know how to Form Structural Sections using Machines | 3.1 | Explain the specific safety precautions to be taken when working with power operated bending and forming equipment such as presses, bending machines and rolling machines in a fabrication environment |
| 3.2 | Explain the general workshop and site safety requirements, statutory regulations; risk assessment procedures and COSHH regulations |
| 3.3 | Describe the correct protective clothing and handling precautions to be taken when working with structural section materials (gloves, eye protection, safety helmets, ear protection) |
| 3.4 | Explain the handling precautions and correct methods of moving or lifting heavy structural section (RSJs, etc.) |
| 3.5 | Describe the hazards associated with power operated bending processes and explain how they can be minimised (such as handling heavy structural materials and components; operating moving equipment; using faulty or badly maintained tools and equipment) |
| 3.6 | Explain the safe working practices and procedures required for operating power operated bending and forming machines |
| 3.7 | Explain how to obtain the necessary structural drawings and bending procedure specifications |
| 3.8 | Explain how to extract information from engineering drawings and related specifications to include symbols and conventions to appropriate BS or ISO standards in relation to work undertaken |
| 3.9 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing |
| 3.10 | Explain the marking out conventions applicable to the bending process (centre lines; bending lines) |
| 3.11 | Describe the various types of power operated bending machines that are used for structural section materials, and typical applications |
| 3.12 | Explain how to prepare and set up the machine for a range of different bends (angled bends, curved sections, twisted sections and straightening of sections) |
| 4 | 2b. Know how to Form Structural Sections using Machines (continued) | 4.1 | Describe the types of bending tools that are used for the various operations and how they are secured and set to the machine’s tool holding device |
| 4.2 | Explain ways of limiting distortion, marking and creases in the finished workpiece |
| 4.3 | Describe the preparations that need to be carried out on the materials prior to bending them |
| 4.4 | Explain the basic characteristics of the materials with regard to the bending operations undertaken |
| 4.5 | Explain why some materials may require a heating process before bending begins |
| 4.6 | Explain the need to take care of the bending tools and equipment; how to recognise faulty or damaged forming tools; how bending and forming tools should be stored |
| 4.7 | Describe the problems that can occur with the bending and forming activities, and explain how they can be avoided |
| 4.8 | Describe the organisational quality control procedures that are used, and explain how to recognise defects in the bends that they produce |
| 4.9 | Explain how to make dimensional and forming inspection checks, and the tools and equipment that can be used |
| 4.10 | Describe the accuracy and limitations of the processes |
| 4.11 | Describe the extent of their own responsibility and explain whom they should report to if they have problems that they cannot resolve |
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